Spring loaded tooling head and method for tire cord application

ABSTRACT

A tooling head for bidirectional tire cord application to an annular surface reciprocates in a forward and a reverse direction across the annular surface. The tooling head includes a housing; a nose block assembly coupled to the housing and reciprocating in an axial direction relative to the tooling head housing; a pair of cord engaging rollers mounted to a remote end of the nose block assembly and moving therewith in a forward and a reverse direction across the annular surface, the rollers positioning at least one cord against the annular surface in the forward and reverse directions; and a biasing element engaging against the nose block assembly for alternatively biasing the rollers against the annular surface.

FIELD OF THE INVENTION

This invention relates generally to an improved apparatus formanufacturing a toroidal carcass ply for a tire and, more specifically,to an applicator head for direct application of a single end cord to anannular tire building surface.

BACKGROUND OF THE INVENTION

Historically, the pneumatic tire has been fabricated as a laminatestructure of generally toroidal shape having beads, a tread, beltreinforcement, and a carcass. The tire is made of rubber, fabric, andsteel. The manufacturing technologies employed for the most partinvolved assembling the many tire components from flat strips or sheetsof material. Each component is placed on a building drum and cut tolength such that the ends of the component meet or overlap creating asplice.

In the first stage of assembly the prior art carcass will normallyinclude one or more plies, and a pair of sidewalls, a pair of apexes, aninnerliner (for a tubeless tire), a pair of chafers and perhaps a pairof gum shoulder strips. Annular bead cores can be added during thisfirst stage of tire building and the plies can be turned around the beadcores to form the ply turnups. Additional components may be used or evenreplace some of those mentioned above.

This intermediate article of manufacture would be cylindrically formedat this point in the first stage of assembly. The cylindrical carcass isthen expanded into a toroidal shape after completion of the first stageof tire building. Reinforcing belts and the tread are added to thisintermediate article during a second stage of tire manufacture, whichcan occur using the same building drum or work station.

This form of manufacturing a tire from flat components that are thenformed toroidally limits the ability of the tire to be produced in amost uniform fashion. As a result, an improved method and apparatus hasbeen proposed, the method involving applying an elastomeric layer on atoroidal surface and placing and stitching one or more cords incontinuous lengths onto the elastomeric layer in predetermined cordpaths. The method further includes dispensing the one or more cords fromspools and guiding the cord in a predetermined path as the cord is beingdispensed. Preferably, each cord, pre-coated with rubber or not socoated, is held against the elastomeric layer after the cord is placedand stitched and then indexing the cord path to a next circumferentiallocation forming a loop end by reversing the direction of the cord andreleasing the held cord after the loop end is formed and the cord pathdirection is reversed. Preferably, the indexing of the toroidal surfaceestablishes the cord pitch uniformly in discrete angular spacing atspecific diameters.

The above method is performed using an apparatus for forming an annulartoroidally shaped cord reinforced ply which has a toroidal mandrel, acord dispenser, a device to guide the dispensed cords alongpredetermined paths, a device to place an elastomeric layer on thetoroidal mandrel, a device to stitch the cords onto the elastomericlayer, and a device to hold the cords while loop ends are formed. Thedevice to stitch the cords onto the elastomeric layer includes abi-directional tooling head mounted to a tooling arm. A pair of rollermembers is mounted side by side at a remote end of the tooling head anddefining a cord exiting opening therebetween. The arm moves the headacross the curvature of a tire carcass built on a drum or core while thecord is fed through the exit opening between the rollers. The rollersstitch the cord against the annular surface as the cord is laid back andforth across the surface, the first roller engaging the cord along afirst directional path and the second roller engaging the cord in areversed opposite second directional path.

The toroidal mandrel is preferably rotatable about its axis and a meansfor rotating is provided which permits the mandrel to indexcircumferentially as the cord is placed in a predetermined cord path.The guide device preferably includes a multi axis robotic computercontrolled system and a ply mechanism to permit the cord path to followthe contour of the mandrel including the concave and convex profiles.

While working well, certain challenges exist in the aforementionedproposed apparatus and method. For example, it would be desirable forthe tooling head to maintain a constant optimal pressure against theannular surface. Excessive pressure can damage the cord or theunderlying layer, resulting in a less than satisfactory cord layer inthe finished tire. Excessive pressure can also break the cord, requiringa re-application of the cord layer and consequently detrimentallyincreasing manufacturing times. On the other hand, too little pressureon the cord may result in a less than optimal adherence of the cord tothe underlying layer. Less than a proper level of adherence between thecord and the underlying layer may allow the cord to shift out ofposition during or after the cord laying procedure, resulting again in acord layer that is defective in the finished tire.

Existing tooling heads, however, have proven less than adequate inmaintaining constant optimal pressure against the annular core surface.Imperfections in the previously applied layers and the fixed spatialdisposition of the rollers relative to the core surface result in avariable contact pressure exerted by the rollers against the annularsurface. The consequence is a less controlled application of the cordagainst the annular surface.

A further drawback in proposed bi-directional tooling heads for laying asingle end cord against an annular core surface is that such toolingheads are undesirably complicated and expensive to build and maintain.Such heads incorporate mechanical fingers and paddles to loop andpressure the cord into the ply compound as the head traverses the coresurface. Controlling the pressure that such mechanisms exert upon thecord and annular surface, however, has proven problematic in view of thecomplexity of the mechanism itself and surface anomalies in thepreviously applied layer(s).

A need, accordingly, remains for an applicator head that is simple toconstruct, operationally reliable and efficient, and effective inbi-directional application of a single end cord to a tire carcass.Furthermore, a need exists for an applicator head that can effectivelyapply a tire cord at a constant optimal pressure against an annular coresurface in order to adjust for surface layer(s) anomalies and thickness.

SUMMARY OF THE INVENTION

Pursuant to one aspect of the invention, a tooling head forbi-directional tire cord application to an annular surface has a noseblock assembly slideably connected to a tooling head assembly. The noseblock assembly moves reciprocally in an axial direction relative to thetooling head housing and includes a cord-engaging element. A cordengaging element moves with the nose block assembly in a forward and areverse direction across the annular surface and is positioned to engageat least one cord against the annular surface in the forward and reversedirections. In accordance with the invention, a biasing element isprovided to engage against the nose block assembly and bias the cordengaging element against the annular surface in the forward and reversedirections.

Pursuant to another aspect of the invention, the cord engaging elementis represented by a plurality of rollers, at least one roller of theplurality of rollers engaging against the annular surface in the forwarddirection and disengaging from the annular surface in the reversedirection. Another aspect includes a tilting mechanism that tilts thenose block assembly between first and second angular positions while thecord engaging element moves respectively in the forward and reversedirections across the annular surface.

Pursuant to yet a further aspect of the invention, the tooling headassembly includes a chamber and the biasing element comprises apneumatic intake in communication with the tooling head assembly chamberfor directing pressurized air against the nose block assembly. The noseblock assembly may thus maintain contact with the annular core surfaceat substantially a constant optimal pressure until the cord layer iscompleted by the tooling head traversing the annular surface in theforward and reverse directions.

According to another aspect of the invention, a method forbi-directional tire cord application to an annular surface is employed,comprising: mounting a tooling head for reciprocal movement in a forwardand a reverse direction across the annular surface, the tooling headhaving a plurality of annular surface engaging roller components at aterminal end at the annular surface; feeding a length of tire cordthrough the tooling head to the terminal end of the tooling head;selectively routing the tire cord between at least one roller componentand the annular surface as the tooling head moves across the annularsurface; and biasing the at least one roller component against theannular surface as the tooling head moves across the annular surface. Amethod may further employed using a pneumatic spring for biasing theroller component against the annular surface at a substantially constantpressure as the tooling head moves across the annular surface.

Definitions

“Aspect Ratio” means the ratio of a tire's section height to its sectionwidth.

“Axial” and “axially” means the lines or directions that are parallel tothe axis of rotation of the tire.

“Bead” or “Bead Core” means generally that part of the tire comprisingan annular tensile member, the radially inner beads are associated withholding the tire to the rim being wrapped by ply cords and shaped, withor without other reinforcement elements such as flippers, chippers,apexes or fillers, toe guards and chaffers.

“Belt Structure” or “Reinforcing Belts” means at least two annularlayers or plies of parallel cords, woven or unwoven, underlying thetread, unanchored to the bead, and having both left and right cordangles in the range from 17° to 27° with respect to the equatorial planeof the tire.

“Circumferential” means lines or directions extending along theperimeter of the surface of the annular tread perpendicular to the axialdirection.

“Carcass” means the tire structure apart from the belt structure, tread,undertread, over the plies, but including beads, if used, on anyalternative rim attachment.

“Casing” means the carcass, belt structure, beads, sidewalls and allother components of the tire excepting the tread and undertread.

“Chaffers” refers to narrow strips of material placed around the outsideof the bead to protect cord plies from the rim, distribute flexing abovethe rim.

“Cord” means one of the reinforcement strands of which the plies in thetire are comprised.

“Equatorial Plane (EP)” means the plane perpendicular to the tire's axisof rotation and passing through the center of its tread.

“Footprint” means the contact patch or area of contact of the tire treadwith a flat surface at zero speed and under normal load and pressure.

“Innerliner” means the layer or layers of elastomer or other materialthat form the inside surface of a tubeless tire and that contain theinflating fluid within the tire.

“Normal Inflation Pressure” means the specific design inflation pressureand load assigned by the appropriate standards organization for theservice condition for the tire.

“Normal Load” means the specific design inflation pressure and loadassigned by the appropriate standards organization for the servicecondition for the tire.

“Placement” means positioning a cord on a surface by means of applyingpressure to adhere the cord at the location of placement along thedesired ply path.

“Ply” means a layer of rubber-coated parallel cords.

“Radial” and “radially” mean directions radially toward or away from theaxis of rotation of the tire.

“Radial Ply Tire” means a belted or circumferentially-restrictedpneumatic tire in which at least one ply has cords which extend frombead to bead are laid at cord angles between 65° and 90° with respect tothe equatorial plane of the tire.

“Section Height” means the radial distance from the nominal rim diameterto the outer diameter of the tire at its equatorial plane.

“Section Width” means the maximum linear distance parallel to the axisof the tire and between the exterior of its sidewalls when and after ithas been inflated at normal pressure for 24 hours, but unloaded,excluding elevations of the sidewalls due to labeling, decoration orprotective bands.

“Shoulder” means the upper portion of sidewall just below the treadedge.

“Sidewall” means that portion of a tire between the tread and the bead.

“Tread Width” means the arc length of the tread surface in the axialdirection, that is, in a plane parallel to the axis of rotation of thetire.

“Winding” means a wrapping of a cord under tension onto a convex surfacealong a linear path.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described by way of example and with reference tothe accompanying drawings in which:

FIG. 1 is a perspective view of a tire making station employing aplurality of ply laying assemblies, each configured pursuant to anaspect of the invention.

FIG. 1A is a perspective view similar to FIG. 1 showing the tire makingstation enclosed within a protective cage.

FIG. 2 is a side elevation view of the tire making station showingspatial dispensation of plural ply laying assemblies about a tire buildcore.

FIG. 3A is an enlarged perspective view of one ply laying assemblydisposed at an initial position relative to a tire build core that ispartially sectioned for illustration.

FIG. 3B is an enlarged perspective view of the ply making assembly shownin FIG. 3A at a subsequent intermediate position along a ply laying pathrelative to the tire build core.

FIG. 3C is an enlarged perspective view of the ply laying assembly shownin FIG. 3A at a subsequent terminal position relative to the tire buildcore.

FIG. 4 is a front elevation view shown in partial transverse section forillustration of a ply laying apparatus configured pursuant to theinvention at the terminal position relative to the tire build core.

FIG. 5 is an enlarged perspective view of ply laying assembly.

FIG. 6 is a rear elevation view of the ply laying assembly.

FIG. 7 is a side elevation view of the ply laying assembly showingsequential operation of the support arm slide mechanism in phantom.

FIG. 8 is a transverse section view through the ply laying apparatus.

FIG. 9 is a side elevation view of the ply laying apparatus co-mountedadjacent a cord tensioning and feed assembly.

FIG. 10 is an enlarged perspective view of the cord tensioning and feedassembly.

FIG. 11 is a bottom plan view of the ply laying assembly.

FIG. 12 is a transverse section view through the ply laying end of armtooling.

FIG. 13A is a transverse section view through the ply laying end of armtooling shown in the retracted position and shown in phantom in theaxially elongated position.

FIG. 13B is a transverse section view through the ply laying end of armtooling of FIG. 13A shown in the axially elongated position.

FIG. 14 is a transverse section view through the ply laying end of armtooling of FIG. 13A shown moving in a tilted forward direction.

FIG. 15 is a transverse section view through the ply laying end of armtooling of FIG. 13A shown moving in a reverse tilted reverse direction.

FIG. 16 is a front right perspective view of the ply laying end of armtooling with portions sectioned for clarity.

FIG. 16A is a partially exploded perspective view of the roller assemblyof the ply laying end of arm tooling.

FIG. 16B is a left side perspective view of the end of arm toolingwithout the outer housing shown for the purpose of illustrating theposition of the shear piston and linkage in the extended position.

FIG. 16C is a left side perspective view of the end of arm toolingwithout the outer housing shown for the purpose of illustrating theposition of the shear piston and linkage in the retracted position.

FIG. 17 is an exploded perspective view of the cord cutting subassemblyof the ply laying end of arm tooling.

FIGS. 18A-D are sequential views of the tire forming mandrel showing thebuild of a ply layer by means of single cord application pursuant to theinvention.

FIGS. 19-28 are representative ply cord patterns that may be applied toan annular core surface pursuant to the invention.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIGS. 1, 1A, and 2, a machine assembly 10 isshown for the construction of a tire on a core assembly 11. The coreassembly 11 is generally of toroidal shape and a tire is formed thereonby the sequential layering of tire components on the toroidal form ofthe core. A platform 12 may be deployed as support for the assembly 10.A drive motor 14 is coupled by a conventional shaft to rotate the coreassembly 11 as tire component layers are sequentially applied to thetoroidal core.

The referenced drawings depict four arm assemblies 16 A-D surroundingthe core assembly in a preferred arrangement. While four assemblies areincorporated in the system embodiment 10, the invention is not to be solimited. A single arm assembly may be used if desired. Alternatively,more or fewer than four assemblies may constitute the system if desired.The four arm assemblies 16 A-D are disposed to surround the coreassembly 10 at a preferred spacing that allows the arm assemblies tosimultaneously construct a cord ply to respective regions of thetoroidal core. Dividing the surface area of the toroidal core into fourquadrants, each assigned to a respective one of the four arm assemblies,allows the cord ply layer to be formed simultaneously to all fourquadrants, whereby expediting the process and saving time andmanufacturing cost.

A core removal assembly 18 is shown disposed to remove the core assembly11 from between the arm assemblies 16 A-D once tire construction on thecore is complete. An appropriate computer control system conventional tothe industry may be employed to control the operation of the system 10including arm assemblies 16 A-D. A control system of the type shown willtypically include a housing 22 enclosing the computer and system controlhardware. Electrical control signals will be transmitted to the system10 by means one or more suitable cable conduit such as that show atnumeral 23.

A cage or peripheral guard structure 24 may enclose the system 10 asshown in FIG. 1A. An additional pendant control unit 26 for the controlcooler unit 20 is mounted to the guard 24. Each of the arm assemblies16A-D is serviced by a cord let off assembly or spool 28, only one ofthe four being shown in FIG. 2 for the sake of clarity. A balancerassembly 30 is associated with each let off assembly 28 for placing cord32 fed from the assembly 28 in proper tension and balance. The cord 32is fed as shown through the balancer assembly 20 to the arm assembly16D.

In FIGS. 3A-C and 4, operation of one arm assembly 16D is sequentiallydepicted and will be readily understood. The arm assembly 16D isconfigured to provide end of arm tooling assembly 34 carried by C-framearm 36, electrically serviced by suitable cabling extending throughcable tray 38. As explained previously, the core assembly 11 isconfigured having a rotational axial shaft 40 and a segmented toroidalcore body 42 providing an annular outer toroidal surface 43. A mainmounting bracket 44 supports the end of arm tooling assembly 34 as wellas a drive motor 46 and clutch assembly 48. As best seen from jointconsideration of FIGS. 4, 5, 6, 7, and 8, the C-frame arm 36 isslideably attached to a z-axis vertical slide member 50 and moves alonga Z-axis to traverse the width of the outer core toroidal surface 43.Movement of the arm 36 along slide member 50 facilitates the laying ofcord on cores for tires of varying sizes. FIG. 3A depicts the armassembly 36 at a beginning position relative to surface 43; FIG. 3B aposition mid-way along the transverse path across surface 43; and FIG.3C a terminal transverse position of assembly 36 at an opposite side ofthe surface 43. FIG. 7 illustrates the movement of arm assembly 36 alongslide 50 to facilitate movement of assembly 36 between the sequentialpositions illustrated in FIGS. 3A-C. Drive shaft 51 is coupled to thearm assembly 36 as seen from FIG. 8 and drives the assembly along theZ-axis path in reciprocal fashion responsive to control instructions.

An end of arm tooling motor 52 is further mounted on arm assembly 36 androtatably drives end of arm tooling shaft 54. The end of arm tooling 34consists of a bi-directional cord laying head assembly 56, anintermediate housing assembly 57, and an upper housing assembly 59. Theend of arm tooling 34 further includes a cord tensioning sub-assembly 58as shown in detail in FIGS. 9 and 10. Sub-assembly 58 includes a drivemotor 60, the motor 60 being mounted on an S-shaped block 62. Thesub-assembly 58 further includes a first pulley 64; a spatiallyadjustable cord pulley 65; and a third pulley 66. An elongate closed-endtensioning belt 68 routes around the pulleys 64, 66 as shown. A cordguiding terminal tube 70 extends from the pulley and belt tensioningregion of assembly 58 through the block 62. An initial cord guidingpassageway 72 enters into the block 62 and guides cord 32 through theblock and into the tensioning region of assembly 58. Belt 68 is routedaround pulleys 64, 66 and is rotated thereby. It will be appreciatedthat the cord 32 is routed as shown between belt 68 and pulley 65 and isaxially fed by the rotation of belt 68 through the assembly 58. Byadjusting the relative position of pulley 65 against the cord 32 andbelt 68, the cord 32 may be placed in an optimal state of tension forsubsequent routing through an applicator head. The tensioning of thecord 32 is thus optimized, resulting in a positive feed through theblock 62 and to an applicator head as described following. Breakage ofthe cord that might otherwise occur from a more or less than optimaltension level is thus avoided. Moreover, slippage of the cord caused bya lower than desired tension in the cord is likewise avoided.Additionally, the subject cord tensioning sub-assembly 58 acts toeliminate pinching of the cord that may be present in systems employingrollers to advance a cord line. Pinching of the cord from a roller feedmay act to introduce a progressive twist into the cord that will releasewhen the cord is applied to a surface, and cause the cord to move fromits intended location. The assembly 58, by employing a belt cordadvance, eliminates twisting of the cord and ensures that the cord willadvance smoothly without impedance.

Referring next to FIGS. 11, 12, 13A, 13B, and 17, the bi-directionalcord laying head assembly 56 will be described. In general, theapplicator head 56 is located at a terminal end of the end of armtooling assembly 34. The head assembly, as described below, functions toapply cord to the annular toroidal core surface 43 in a preselectedpattern as one layer in the plurality of layers built upon the core 42during construction of a tire. A pair of applicator guide rollers 74, 76are rotatably mounted in-line to a terminal end of the end of armtooling 34, the rollers defining a cord outlet 78 therebetween with thepivot shafts of the rollers being preferably, but not necessarily,substantially co-axial. More or fewer rollers may be employed if desiredpursuant to the practice of the subject invention. The bi-directionalcord laying head 56 is constructed to provide a final cord guide tube 80extending axially to a remote end in communication with the cord outletopening 78 between the rollers.

The intermediate assembly 57 includes a pre-loaded coil spring 82 thatseats within a spring housing 84 residing within an outer housing block85. The bi-directional cord laying head assembly 56 is placed in adownward bias against the surface 43 by the pre-loaded coil spring 82.O-rings 86 A-F are suitably located between adjacent housing blockelements. The intermediate assembly 57 further includes a lower housing88 receiving a housing block 89 therein. A terminal end of the block 89is closed by an end cap 90 with the intersection sealed by means ofO-rings 91. The block 89 represents a plunger, or piston, slideablycontained within the outer housing 88 that moves axially relative to theend of arm tooling for a purpose explained below. The end of arm tooling34 is pivotally mounted to the bracket 62 and reciprocally rotated bymeans of drive shaft 54 in the direction 69 as will be appreciated fromFIG. 9.

FIGS. 11, 12, 13A, and 13B depict in section the end of arm tooling 34including assemblies 56, 57, and 59. As shown, plural intake portals 92,94, and 96 extend into the tooling assembly at respective axiallocations; cylinder 92 representing a pressurized air inlet forassisting in the feeding of a severed cord end down the axial passagewayof the end-of-arm assembly; cylinder 94 providing air pressure andforming an air spring by which the head assembly of the end of armtooling is maintained at a constant pressure against the annular surfaceof the core; and cylinder 96 providing a pressurized air inlet that,upon actuation, initiates a shearing of the cord. The rollers 74, 76mount to a nose block 97 that is slideably connected at a lower end ofhousing 89 by assembly pin 67. Pin 67 is keyed within a vertical slot inthe housing 89 and prevents the nose block 67 from rotating. The block67 and the rollers 74, 76 are thus maintained in an aligned orientationto the surface 43 of the core.

From FIG. 9, it will be appreciated that the end-of-arm tooling assembly34 is pivotally mounted to the bracket 62 and is fixedly coupled tomotor shaft 54. Shaft 54 is driven rotationally by a computer controlledservo-motor (not shown) in conventional fashion. A rotation of the shaft54 translates into pivotal movement of assembly 34. As the assembly 34pivots, the rollers 74, 76 tilt or pivot backward and forward,alternatively bringing the rollers into contact with the core surface43.

It will further be appreciated from FIGS. 13A and 13B, and FIGS. 12-D,that the piston, or plunger, 89 moves axially within the assemblyhousing 88 in reciprocal fashion. Piston 89 moves independently of thebi-directional head 56. Thus, head 56 can remain in continuous contactwith the core surface 43 at a constant, optimal pressure maintained bypressure intake 94. As head 56 and surface 43 remain in contactingengagement, the piston 89 is free to move axially within housing 88under the influence of spring 82 between the extended position shown inFIG. 13B and FIG. 16C, and the axially retracted position shown in FIG.13A and FIG. 16D. Spring 82 is in a compressed, pre-loaded conditionwith the piston 89 in the retracted axial position of FIGS. 13A and 16D,under load from pressure at intake 96. Upon removal or reduction of airpressure at intake 96, plunger block 89 moves to the extended positionshown in FIGS. 13B and 16C, and spring 82 extends. A resumption ofcontrolled air pressure at intake 96, under computer control, pressurespiston 89 into the retracted position and reloads spring 82. Linearmovement of the plunger block 89 is along the center axis of the end ofarm tooling 34.

The final guide tube 80 extends along the center axis of the end-of-armtooling 34 and, as will be understood from FIGS. 13A and 13B, the cord32 is routed along the center axis of the upper assembly 59, theintermediate assembly 57, and the bi-directional cord laying headassembly 56 of the tooling 34 to exit from the cord outlet opening 78between rollers 74, 76 (FIGS. 11, 12). The cord 32 thereby is positionedand pressured by the rollers 74, 76 against the core surface 43 in apreferred pattern. Depending upon the pattern of the cord layer to beapplied to surface 43, the process of applying the court will requirethat the cord be cut one or more times. A preferred cutting mechanismwill be described as follows.

With reference to FIGS. 15B, 16, 12, and 17, the upper assembly 59includes a cable shear assembly 98, activated by a pair of lever arms102,104 that extend axially along opposite sides of the piston 89 withinhousing 88. The upper assembly 59 includes a mounting base flange 100that mounts to a bearing plate 101 (FIG. 9) by means of screws 108, 110.The bearing plate 101 is rotatably mounted to the end bracket 62. Asdescribed previously, the end of arm tooling 34 may thus be rotated bymotor driven shaft 54. It will be appreciated from FIG. 17 that thespring 82 seats within spring housing 84 enclosed by spring end cap 112.A forward end of spring 82 seats within the end cap 112. End cap 112includes a circular protrusion 114 and a through bore 16. End cap 112 iscontained within the piston 89 as shown. O-ring 118 and washer 120 areinterposed against the forward end of the spring 82 within the cap 112.

The housing block 85 includes an axial passageway 128. A recessedperipheral ledge 122 circumscribes a forward end of the passageway 128and a through bore 124 extends into and through the housing ledge 122. Aslide pin 126 projects through the bore 124 of housing 85, the bore 116of cap 112, and into the housing 89 as shown. Piston 89 is thusslideably coupled to the block 85 and moves reciprocally in an axialdirection relative thereto as described above.

A transverse bore 130 extends through housing 85 from side to side incommunication with passageway 128. Mounting flanges 132, 134 extendlaterally from the housing 85 and mounting screws 134 project throughthe flanges and into housing 88 to secure housing 85 to housing 88. Thecord cutting assembly 98 includes a tubular member 136 rotatablyresiding within the transverse bore 130 and projecting from oppositesides of the housing 85. An attachment lug 138 projects outward from anend of the tubular member 136 and carries an inward facing attachmentstud 139. The tubular member 136 has locking flanges 140 at an oppositeend and a centrally disposed axial through bore 142. A transverse bore144 having a funnel shaped guide entry 145 is positioned to extendthrough the tubular member 136.

A connector block 146 is attached to an end of the tubular member 136and includes a locking socket 148 engaging the locking flanges 140 ofmember 136. An attachment stud 150 extends inwardly from the block 146.Piston 89 is configured having a cylindrical rearwardly disposed socket152 stepping inward to a forward smaller diametered cylindrical portion154. Outwardly projecting pin members 156 extending from opposite sidesof the cylindrical portion 154 of the piston 89. As will be appreciated,forward ends 158 of pivot arms 102, 104 fixedly attach to the pins 156and rearward ends of the arm 102, 104 fixedly attach through the studs150, 139, respectively, to flanges 146, 138 of the tubular component136.

Tubular member 136 resides within the transverse bore 130 of the block85 and rotates freely therein. The ends of member 136 are journalled tothe piston 89 through lever arms 102, 104. The funnel shaped entry 145is positioned facing axially rearward of assembly 34. The cord 32 isdispensed and routed downward through entry 145 of member 136 and exitsfrom the transverse bore 144 along the longitudinal center axis of theend of arm tooling assembly 34. As described previously, spring 82 is ina pre-loaded, state of compression between housing 85 and piston 89while the cord 32 is applied in a predesigned pattern to the annularouter core surface 43. At the completion of the cord laying sequence orat required interim points in the application process, the cord 32 maybe severed through the operation of shear assembly 98. An axial movementof the piston is initiated by a reduction of air pressure at intake 94.Spring 82 thereupon is uncoils and influences the piston 89 axially awayfrom the housing 85. As the piston 89 moves away from the housing 85,the lever arms 102, 104 pull against the ends of the tubular member 136and impart rotation thereto within housing block 85. As the member 136rotates, edges defining the funnel shaped entry 145 are rotated intosevering engagement against the cord 32 extending through the member136. The cord 32 is thereby severed. The free end of cord 32, subsequentto the severing procedure, is generally in an axial alignment with thetooling assembly 34.

To re-route the cord 32 down the assembly 34 in order to resume layingcord, air pressure is re-applied through intake 94 and piston 97 isforced into the higher, retracted position of FIG. 13A, whereuponrecompressing spring 82. Movement of the piston 89 into the retractedposition causes the lever arms 102, 104 to rotatably return the tubularmember 136 into its normal orientation within block 85. So oriented, theshearing edges defining funnel entry 145 of member 136 are in anon-contacting relationship to cord 32 and funnel entry 145 andtransverse bore 144 are axially aligned with the center axis of toolingassembly 34. The severed end of cord 32 is thereafter re-routed down theaxis of tooling assembly 34 to exit from the gap 78 between rollers 72,74. To assist in the re-routing of the free end of cord 32, pressurizedair is introduced through intake 92 and the forced air pushes the freeend of the cord 32 along its axial path. The time required tore-position the end of the cord 32 at the outlet 78 is thereby reducedand cycle time minimized. The free severed end of cord 32 upon exitingbetween rollers 74, 76 is thus positioned for application to the coresurface as a smooth linear feed of the cord 32 through the end of armtooling is resumed.

Rollers 74, 76 are shown in FIG. 16 A as rotationally mounted torespective axial center shafts 166, 168. Shafts 166, 168 mount between aflange extension 170 of the nose block 97 and a retainer 172. Sodisposed, the rollers 74, 76 are axially parallel and spaced apart adistance sufficient to allow the cord 32 to pass therebetween. Theretainer 172 includes adjacent sockets 174, 176 that receive upper endsof the shafts 166, 168 therein. An assembly aperture 178 projectsthrough a rearward surface 182 of retainer 172 as shown. Each of therollers 74, 76 is configured to provide a circumferential channel 180having a sectional profile and dimension complimentary with thesectional configuration of cord 32. The nose block 97 receives the cordguide tube 80 therethrough with a forward end of tube 80 disposedadjacent the gap 78 between rollers 74, 76.

Assembly of the end of arm tooling 34 will be readily apparent fromFIGS. 13 A,B; 16, and 17. The nose block 97 is fixedly coupled to thehousing 88 by the pin 67. The motor shaft 54 rotates reciprocally andcauses the end of arm tooling to resultantly reciprocally rotate throughan angular travel of plus or minus three to eight degrees. A greater orlesser range of pivotal movement may be used if desired. Pivotalmovement of commensurate angular travel of in-line rollers 72, 74 isthus effected as best seen from FIG. 9. Each roller 72, 74 arealternatively brought into and out of engagement against the coresurface 43 through the pivotal movement of assembly 34. The pressureapplied by each roller 72, 74 against the surface 43 are controlledthrough application of appropriate air pressure through the intakeportal 94.

As seen from FIGS. 3A-C; 5; and 7, end of arm tooling 34 mounts to theC-frame arm 36 and are carried thereby toward and away from the surface43 of core 42. The C-frame arm 36 is slideably mounted to the Z-axisslide 50 and reciprocally moves end of arm tooling 34 laterally acrossthe surface 43 in a predefined pattern. Adjustment in the Z axis alongslide 50 is computer controlled to coordinate with the other axis ofadjustment of end of arm tooling 34 to allow for the application of cordto cores of varying sizes. The cord 32 is dispensed from cord let-offspool 28, through a conventional balancer mechanism 34 and to the armassembly. The end of cord 32 is routed at the end of arm cord tensioningassembly 58 (FIGS. 9 and 10) and then into the axial passageway throughend of arm tooling assembly 34. Upon entering assembly 34, the cord 32passes through the tubular member 136 of the cable shear assembly 98 andthen proceeds along the axial guide passage 80 to the cord outlet 78between rollers 74, 76. The cord is received within a circumferentiallylocated roller channel 180 in each roller 74, 76, the roller receivingthe cord being dependent upon the intended direction of travel of thecord across surface 43 pursuant to the predefined pattern. Appropriatepressure of the cord 32 by either roller 74 or 76 against a pre-appliedcarcass layer on core 42 causes the cord to adhere to the carcass layerat its intended location, thus forming the designed cord layer pattern.

Referring to FIGS. 12, 13B, 14, and 15, the alternative tiltingoperation of the end of arm tooling in regard to rollers 74, 76 will beexplained. The rollers 74, 76 tilt along an angular path represented byangle θ (FIGS. 14 and 15) relative to the centerline of the end of armtooling. Alternatively one or the other roller is in a dependentposition relative to the other roller as a result of the pivotalmovement of assembly 34. In a forward traverse of the tooling assemblyacross a carcass layer mounted to the core surface 43, one of therollers will engage the cord 32 within roller channel 180 and stitch thecord 32 against the layer. For a reverse traverse of the tooling headacross the carcass layer, the assembly 34 is tilted in a reversedirection to disengage the first roller from the cord 32 and place thesecond roller into an engaging relationship with cord 32. The secondroller then effects a stitching of the cord 32 against the carcass layermounted to core 42 in a reverse traverse.

The reciprocal pivotal movement of the end of arm tooling 34 iscarefully coordinated with rotational indexing of the core 42 andlateral movement of the tooling assembly 34. Referring to FIGS. 5 and 6,it will be appreciated that the subject assembly 34 in combination withthe core drive constitutes a system having three axis of rotation. Afirst axis is represented by a pivoting of assembly 34 through anangular tile by the drive shaft 54. Shaft 54 is preferably driven by acomputer controlled servo-motor 52. A second axis of rotation is thelateral rotation of the assembly 34 driven by motor 46. Motor 46 ispreferably, but not necessarily a computer controlled ring motor that,responsive to computer generated control signals, can accurately indexthe assembly 34 along a rotational path following the outer surface 43of the core 42. A third axis of rotation is the indexing of the corespindle 42 by motor 14 (FIG. 1). Motor 14 is preferably, but notnecessarily a ring motor that, responsive to computer generated controlsignals, can accurately index the core 42 in coordination with the ringmotor 46 rotationally driving the assembly 34.

The arm assembly 16 A, carrying end of arm tooling 34, is furtheradjustable along a linear path representing a z-axis as shown in FIGS.5,6, and 7. The arm assembly 16A travels along the slide 50 controlledby a timing belt drive 49. Movement of the assembly 16 A along slide 50is computer controlled to correlate with the size of the core on whichthe cord is applied. One or more computers (not shown) are employed tocoordinate rotation of core 42 (by ring motor 14); rotation of end ofarm tooling assembly 34 (by ring motor 46); linear path adjustment ofassembly 16A along the Z-axis (by timing belt drive of assembly 16Aalong slide 49); and tilting adjustment of assembly 34 (by servo-motor52). The assembly thus precisely controls the movement of assembly 16Ain three axis of rotation and along a linear path (slide 50) to enabletooling assembly 34 to accurately place cord 32 in an intended patternon a surface 43 of a core 42 of varying size without need forspecialized equipment to form a loop in the cord at the end of eachtraverse. Creation of the loop at the conclusion of each traverse isaccomplished by an indexed controlled rotation of the core 42. Thus, thecord laying assembly functions to form the loop without the need for afinger mechanism to engage, press, and release the cord. The pattern ofcord applied to the carcass layer upon core 42 may thus be tailored toprovide optimum performance while conserving cord material, resulting inreduced cost of manufacture.

As will be appreciated, a reciprocal pivoting movement of the end of armtooling head that alternately places one of the rollers 74, 76 intoengagement with cord 32 while disengaging the opposite roller results inseveral significant advantages. First, in disengaging one of the rollersfrom the carcass layer, the frictional drag of the disengaged roller iseliminated. As a result, the associated drive motor that drives the endof arm tooling may operate with greater speed and efficiency.Additionally, redundant and unnecessary engagement of the disengagedroller from the cord 32 with the underlying elastomeric layer and thecord is eliminated, reducing the potential for damage to both the cord32 and the underlying carcass layer. Moreover, in utilizing dual rollersmounted in-line, the speed of cord application is at which the cord 32is applied to the carcass may be improved and the drive mechanismsimplified.

It will be appreciated that the application head portion of the tooling34 is air spring biased against the surface 43 of core 42 during theapplication of cord 32 through pressurized intake 94. The air springcreated by intake 94 exerts a substantially constant force through nosehousing 97 to rollers 74, 76. The biasing force upon rollers 74, 76 isapplied to cord 32 as described above, and serves to pressure the cord32 against a carcass layer previously applied to the core surface 43.The tackiness of the pre-applied layer retains the cord 32 at itsintended placement. A more secure placement of the cord 32 results, andthe potential for any unwanted, inadvertent post-application movement ofthe cord 32 from the underlying carcass layer is minimized. At theappropriate time for severing the cord 32 by means of the shearingassembly 98, separation of housings 89 and 85 is effected as shown inFIGS. 15B, 16, 12-D as described previously.

As described previously, to reposition the severed end of the cord 32for another application cycle, pressurized air is introduced throughintake portal 92 and pneumatically forces the free cord end down theaxial passageway 80 to the cord outlet 78 between rollers 74, 76.Application of the cord to the carcass layer on the core 42 may thenrecommence.

With reference to FIGS. 1, 1A, and 2, it will further be appreciatedthat a plurality of like-configured arm assemblies 16 A-D may, ifdesired at the option of the user, be deployed at respectivecircumferential locations about the core 42 in operable proximity to thecore surface 43. Each of the plurality of arm assemblies is assigned aspecific region of the annular core surface 43. The plural armassemblies may then simultaneously apply a cord layer pursuant to theabove recitation to its respective assigned region. In segmenting thecord annular surface 43 between multiple arm assemblies andsimultaneously applying the cord by means of the arm assemblies, afaster cycle time results. While four arm assemblies 16 A-D are shown,more or fewer arm assemblies may be deployed if desired.

Referring to FIGS. 18A-D, 19-27. to advance the cords 32 on a specifiedpath 190, the end of arm tooling mechanism 34 which contains the tworollers 74, 76 forms the cord outlet 78 which enables the cord path 190to be maintained in this center. As illustrated, the cords 32 are heldin place by a combination of embedding the cord into an elastomericcompound 192 previously placed onto the toroidal surface 43 and thesurface tackiness of the uncured compound. Once the cords 32 areproperly applied around the entire circumference of the toroidal surface43 a subsequent lamination of elastomeric topcoat compound (not shown)can be used to complete the construction of the ply 194. It will beappreciated that more than one cord layer may be applied to the core 42,if desired or required. Additional elastomeric layers may be added tothe core and additional cord layers applied as described above.Optionally, if desired, the top or bottom coat of elastomeric materialmay be eliminated and the cord applied in successive layers to formmultiple plies on the core 42.

As illustrated and explained previously, the first roller 76 will embedthe cord 32 on a forward traverse across the toroidal surface 43 asillustrated in FIG. 14. Once the cord path 190 has been transferredacross the toroidal surface 43 the mechanism 34 stops and the cord 32 isadvanced along the toroidal surface 43 by rotation of the core 42. Themechanism 34 then reverses its path 190 forming a loop 196 in the plycord path 190. At this point a tilting of the end of arm tooling headblock 97 causes the first roller 76 of the pair to disengage and thesecond roller 74 to engage the cord 32 to pull the cord 32 back acrossthe toroidal surface 43. In the preferred embodiment the toroidalsurface 43 is indexed or advanced slightly allowing a circumferentialspacing or pitch (P) to occur between the first ply pathway down in thesecond return ply path. The loop 196 that is formed on the reversetraverse is slightly shifted to create the desired loop position. Alooped end 196 may be formed and the second ply path 190 may be laid onthe toroidal surface 43 parallel to the first ply path, or othergeometric paths may be created by selective variation in the coreindexing (rotation) coupled with the speed at which the end of armtooling head traverses the core surface 43 in the forward and/or reversedirections.

The process is repeated to form a series of cords 32 that are continuousand which have the intended preselected optimal pattern. For example,without intent to limit the patterns achievable from the practice of theinvention, the toroidal core 42 with the toroidal surface 43 with anelastomeric compound 192 laminated onto it may be indexed or advanceduniformly about its axis with each traverse of the pair of rollers 74,76to create a linearly parallel path 190 uniformly distributed about thetoroidal surface 43. By varying the advance of the cord 32 as themechanism 34 traverses, it is possible to create non-linear parallelcord paths 190 to tune tire stiffness and to vary flexure with the load.

Preferably the cord 32 is wrapped around the tensioner assembly 58 toadjust and maintain the required tension in the cord 32 (FIG. 10). Thepulley 65 is laterally adjustable to alter the tension in the belt 68which, in turn engages the cord 32 passing beneath pulleys 64, 66 andover pulley 65. More or less tension in the belt 68 translates into moreor less tension in the cord 32. If the cord 32 is too tight it will liftthe cord from the coat laminate when the rollers 74, 76 reversedirection. If it is too loose it will not create a loop at the correctlength. Moreover, the amount of tension applied has to be sufficientlysmall that it does not lift the cords 32 from their placed position onthe toroidal surface 43. The cord 32 under proper tension will rest onthe toroidal surface 43 positioned and stitched to an elastomeric layer192 such that the tack between the cord 32 and the elastomeric layer 192is larger than the tension applied by the tensioner assembly 58. Thispermits the cords 32 to lay freely onto the toroidal surface 43 withoutmoving or separating during the ply construction period.

With reference to FIGS. 18A-D, depicted is a three dimensional view of acylinder representing how the ply path 190 is initiated along what wouldgenerally be considered the bead region 198 of the carcass 194 along thetire sidewall 200 toward the shoulder region 202 of the toroidal surface43 and then traverses across the toroidal surface 43 in an area commonlyreferred to as the crown 204 as illustrated in FIG. 18B. In FIG. 18B itwill be noticed that the ply cord path 190 is laid at a slight angle.While the ply path 190 may be at any angle including radially at 90° orless, the ply path 190 also can be applied in a non-linear fashion. Asshown in FIG. 18C, once the ply cord 32 is traversed completely acrossthe toroidal surface 43 and down the opposite side the loop 196 isformed as previously discussed and the cord 32 is brought back acrossthe crown 204 as shown in FIG. 18C. In FIG. 18D the cord 32 thenproceeds down the tire sidewall 200 towards the bead region 198 where itis turned forming a loop 196 as previously discussed and then traversesback across the toroidal surface 43 in a linear path 190 as illustratedthat is parallel to the first and second ply cord paths 190. Thisprocess is repeated in FIGS. 19 and 20 as the toroidal surface 43 isindexed, creating a very uniform and evenly spaced ply cord path 190.

Other cord patterns may be devised and implemented using the end of armtooling 34 of the present invention. The speed at which core 42 isrotated and or the speed of the traverse travel of the tooling head 56across surface 43 may be varied in order to generate patterns ofpreferred configuration. By way of example, cord laying patterns aredepicted in FIGS. 19-27 showing sample cord pattern configurations. Thepresent invention is not intended to be limited to those patternsdepicted and other patterns obvious to those skilled in the art may bedevised.

With reference to FIGS. 13 and 16A, it will be noted that the nose block97 is slidably attached to the tooling head housing 88 by means of setpin 67. The nose block 97 reciprocally moves in an axial direction asindicated in phantom in FIG. 13A. The plunger or piston 89 resideswithin an internal chamber of the housing 88 and moves axially inreciprocal fashion to activate the cord cutting mechanism 96 asdescribed above. The axial movement of the plunger 89 is independent ofthe movement of nose block 97. That is, axial movement of plunger 89 maybe effected to actuate the cutting assembly mechanism without displacingthe relative position of the nose block 97 to annular core surface 43.

The intake portal 94 communicates with the internal chamber of thehousing 88 and introduces pressurized air into the chamber to create anair spring. The pressurized air within the chamber applies asubstantially constant optimal pressure against the nose block 97. Theapplied air pressure against the nose block thus biases the rollers 74,76 against the annular core surface 43 and rollers 74, 76 pressure thecord 32 against the surface 43 with an optimal pressure.

The end of arm tooling head 34 thus maintains a constant optimalpressure against the annular surface and a proper placement of the cordonto the underlying layer results. Imperfections in the previouslyapplied layers create surface anomalies that make the application of thecord at a constant pressure problematic. By applying a constant airpressure to the nose block 97 through intake 94, surface anomalies donot interfere with an accurate placement of the cord 32 with the optimallevel of roller pressure.

Moreover, it will be noted that the end of arm tooling head 34 isrelatively simple in construction and is therefore less expensive tomanufacture and maintain when compared against tooling heads thatincorporate mechanical fingers and paddles to loop and pressure the cordinto the ply compound as the head traverses the core surface. Thepneumatic spring created by intake 94 allows the tooling head tomaintain a constant pressure against the annular core surface in ahighly controlled manner. Contact between the rollers 72, 74 and thesurface 43 may thereby be maintained throughout the creation of acomplete cord layer and the air spring created by intake 94 compensatesfor any surface anomalies in the immediately underlying layer or inlayers previously applied to the core.

From the foregoing, the invention achieves a tooling head forbi-directional tire cord application to an annular surface that couplesa nose block assembly (such as block 97 and rollers 72, 74) a toolinghead assembly (such as housing 88). The nose block assembly movesreciprocally in an axial direction relative to the tooling head housingand includes a cord engaging element (such as rollers 72, 74) mounted toa remote end. The cord engaging element moves with the nose blockassembly in a forward and a reverse direction across the annular surfaceand is positioned to engage at least one cord 32 against the annularsurface 43 in the forward and reverse directions. In accordance with theinvention, a biasing element (intake 94) is provided to engage againstthe nose block assembly and bias the cord engaging element against theannular surface in the forward and reverse directions.

The cord engaging element may be represented by a plurality of rollers72,74, at least one roller of the plurality of rollers engaging againstthe annular surface in the forward direction and disengaging from theannular surface 43 in the reverse direction. A tilt mechanism fortilting the nose block assembly (shaft 54) between first and secondangular positions may further be utilized while the cord engaging meansmoves respectively in the forward and reverse directions across theannular surface.

The tooling head assembly includes a chamber and the biasing elementcomprises a pneumatic intake 94 in communication with the tooling headassembly chamber for directing pressurized air into housing 88 andagainst the nose block assembly. Contact between the nose block assemblyand the annular core surface 43 is thus maintained constant at anoptimal pressure until the cord layer is completed by the tooling headtraversing the annular surface in the forward and reverse directions.

Variations in the present invention are possible in light of thedescription of it provided herein. While certain representativeembodiments and details have been shown for the purpose of illustratingthe subject invention, it will be apparent to those skilled in this artthat various changes and modifications can be made therein withoutdeparting from the scope of the subject invention. It is, therefore, tobe understood that changes can be made in the particular embodimentsdescribed which will be within the full intended scope of the inventionas defined by the following appended claims.

1-13. (canceled)
 14. A method for bidirectional tire cord application toan annular surface, the method comprising: mounting a tooling head forreciprocal movement in a forward and a reverse direction across theannular surface, the tooling head having a plurality of annular surfaceengaging roller components at the annular surface; feeding a length oftire cord through the tooling head to the terminal end of the toolinghead; selectively routing the tire cord between at least one rollercomponent and the annular surface as the tooling head moves across theannular surface; and biasing the at least one roller component againstthe annular surface as the tooling head moves across the annularsurface.
 15. A method according to claim 14, wherein further comprisingutilizing a pneumatic spring for biasing the roller component againstthe annular surface at a substantially constant pressure as the toolinghead moves across the annular surface.
 16. A method according to claim14, further comprising: pivotally reorienting the tooling head between afirst orientation and a second orientation at the conclusion of toolinghead movement in the forward and reverse directions.
 17. A methodaccording to claim 16, wherein further comprising rotationally indexingthe annular surface in coordination with the pivotal reorientation ofthe tooling head between the first and second orientations.